Profile No.

: 273 NIC Code: 27102

CURRENT TRANSFORMER

1. INTRODUCTION:

A current transformer (CT) is a type of transformer that is used to measure AC current. It

produces an alternating current (AC) in its secondary which is proportional to the AC current
in its primary. Current transformers, along with voltage or potential transformers are
Instrument transformer. Instrument transformers scale the large values of voltage or current
too small, standardized values that are easy to handle for instruments and protective relays.
The instrument transformers isolate measurement or protection circuits from the high
voltage of the primary system. A current transformer provides a secondary current that is
accurately proportional to the current flowing in its primary. The current transformer
presents a negligible load to the primary circuit.

Current transformers are the current sensing units of the power system. Current
transformers are used at generating stations, electrical substations, and in industrial and
commercial electric power distribution.

2. PRODUCT & ITS APPLICATION:

Current Transformer
Current Transformers are providing measuring and protective class accuracies. Low tension
bar primary CT in moulded case is housed in an attractive & rigid abs case (color as
required). These CT’s are suitable for bus bars up to 40 x 12mm and round conductors up to
35mm.

Instrument Transformers
Instrument Transformers are manufactured using high quality raw materials and advanced
technology with state-of-the-art infrastructure facility. These transformers are easy to install
owing to their light-weight design and compact size. Their rugged structure makes them
suitable for repeated use.

L.T. Current Transformer

The low tension current transformer is used mainly for the conversion of the primary current
on its secondary side & thus extends the range of instruments/protective devices connected
in its secondary circuit. A C.T. by its very nature of application isolates the devices connected
in its secondary circuit from the network system into which the C.T. is connected.
There are three basic types of current transformers: wound, toroidal and bar.
 Wound Current Transformer – The transformers primary winding is physically
connected in series with the conductor that carries the measured current flowing in
the circuit. The magnitude of the secondary current is dependent on the turn’s ratio
of the transformer.
 Toroidal Current Transformer – These do not contain a primary winding. Instead, the
line that carries the current flowing in the network is threaded through a window or
hole in the toroidal transformer. Some current transformers have a “split core” which
allows it to be opened, installed, and closed, without disconnecting the circuit to
which they are attached.
 Bar-type Current Transformer – This type of current transformer uses the actual
cable or bus-bar of the main circuit as the primary winding, which is equivalent to a
single turn. They are fully insulated from the high operating voltage of the system
and are usually bolted to the current carrying device.

USES:
Current transformers are used extensively for measuring current and monitoring the
operation of the power grid. Along with voltage leads, revenue-grade CTs drive the electrical
utility's watt-hour meter on virtually every building with three-phase service and single-phase
services greater than 200 amperes. High-voltage current transformers are mounted on
porcelain or polymer insulators to isolate them from ground. Some CT configurations slip
around the bushing of a high-voltage transformer or circuit breaker, which automatically
canters the conductor inside the CT window. Current transformers can be mounted on the
low voltage or high voltage leads of a power transformer. Sometimes a section of a bus bar
can be removed to replace a current transformer. Often, multiple CTs are installed as a
"stack" for various uses. For example, protection devices and revenue metering may use
separate CTs to provide isolation between metering and protection circuits, and allows
current transformers with different characteristics (accuracy, overload performance) to be
used for the devices. The burden (load) impedance should not exceed the specified
maximum value to avoid the secondary voltage exceeding the limits for the current
transformer. The primary current rating of a current transformer should not be exceeded or
the core may enter its nonlinear region and ultimately saturate. This would occur near the
end of the first half of each half (positive and negative) of the AC sine wave in the primary
and would compromise the accuracy.

3. DESIRED QUALIFICATIONS FOR PROMOTER:

Graduate in any discipline. The knowledge of engineering design and electrical parts and the
characteristic of transformer are necessary.

4. INDUSTRY LOOK OUT AND TRENDS

Electric equipment industry contributes over 2% of GDP which is projected to increase to

about 12% in 2015 according to a study by Frost & Sullivan. During the period, consumption
of electrical equipment is estimated to increase from over USD 28 bn now to USD 363 bn,
growing at a CAGR of about 30%. It is also expected that during 2010-2015, the Indian
equipment manufacturing will grow at 5.5 times the growth rate of global electronic
equipment production.

The electrical equipment and accessories industry, with its highly diversified content, may be
broadly segmented into (i) generation equipment, (ii) transmission equipment, and (iii)
distribution equipment. The equipments and accessories under these segments include
motors, turbines, gene-rators, switchgears, transformers, circuit breakers, induction motors,
power capacitors, meters, transmission towers. Besides these, the spectrum covers a whole
range of power cables including XLPE and AAC and ACSR conductors and electrical consumer
products like fans, electric lamps, exhausts and domestic appliances and accessories.
Inverter, gensets, UPS also fall under its domain.

The growth of the industry is directly related to the development of power generation and
distribution. India's generation capacity of 2,300 MW in 1950 expanded to over 116,500 MW
including non-utilities at the end 2000-01. The total installed capacity of electric power
generation further increased to 141,080 MW in 2007-08 (up to January 2008) compared to a
capacity of 128,000 MW during the same period in 2006-07. The Eleventh Plan has targeted
a capacity addition of 78,570 MW.

With some fast moves at launching fast track projects to augment supplies, the Indian
industry needs to improve its competitiveness. The Indian market is growing and
multinationals with newer technologies are now more active.

5. MARKET POTENTIAL AND MARKETING ISSUES, IF ANY:

The Instrument Transformers industry in India manufactures current transformers and

voltage transformers of various rating from 0.66 kV to 765 kV, for indoor and outdoor
applications. The industry also exports instrument transformers in the range of indoor up to
36 kV and outdoor above 12 kV. Over the past 2 years, the industry has also demonstrated
its capabilities by manufacturing 1200 kV CVT for 1200 kV test station. Over the last year,
generally there was slowdown in the requirement of equipment and hence no improvement
in the industry scenario. Even the market size was observed to be shrinking in 400 kV
segment as well as 220/120 and 66 kV segments. The reduction in 765 kV segment was
observed, mainly due to shift from AIS to GIS. However no major threat was observed due
to exports. In the changed industry scenario, many surge arrester players have started
manufacturing CTs and many players have entered the field with manufacturing of CTs up to
220 kV range. It was also observed that the customers raising the quality standards and
imposing stringent quality acceptance criteria for these products.
 6. RAW MATERIAL REQUIREMENTS:

The basic raw material 'Cold Rolled Grain Oriented (CRGO) Steel' is used for manufacturing
both Lamination and Wound Cores. The same is imported from reputed overseas mills of
Japan, Korea, Russia, Germany, France, U.K., Brazil and U.S.A, in various grades of different
permeability. . Basically, there are many types of CRGO Steel eg. M-3, M-4, M-5 and M-6
grade and HI-B Material. These raw materials are imported in the forms of mother coils
having standard width of 750/1100 mm. CRGO material has the least figure of maximum
core loss in the rolling direction. With the increased shearing angle to the rolling direction,
the core loss at any particular flux density goes up and becomes generally highest in the
transverse direction. Because of this it is possible to use CRGO in static electrical machines
which include all types of power transformers, distribution transformers, reactors, audio
transformers and current transformer.

The case of CT's is made of polycarbonate, which is flame retardant and non-drip and
conforms to UL 94 V-0. Polycarbonate is a very tough and lightweight engineering plastic
material which has got the best mechanical properties very close to a metallic housing.

7. MANUFACTURING PROCESS:

Bar-type current transformers have terminals for source and load connections of the primary
circuit, and the body of the current transformer provides insulation between the primary
circuit and ground. By use of oil insulation and porcelain bushings, such transformers can be
applied at the highest transmission voltages. Ring-type current transformers are installed
over a bus bar or an insulated cable and have only a low level of insulation on the secondary
coil. To obtain non-standard ratios or for other special purposes, more than one turn of the
primary cable may be passed through the ring. Where a metal shield is present in the cable
jacket, it must be terminated so no net sheath current passes through the ring, to ensure
accuracy. Current transformers used to sense ground fault (zero sequence) currents, such as
in a three-phase installation, may have three primary conductors passed through the ring.
Only the net unbalanced current produces a secondary current - this can be used to detect a
fault from an energized conductor to ground. Ring-type transformers usually use dry
insulation systems, with a hard rubber or plastic case over the secondary windings. For
temporary connections, a split ring-type current transformer can be slipped over a cable
without disconnecting it. This type has a laminated iron core, with a hinged section that
allows it to be installed over the cable; the core links the magnetic flux produced by the
single turn primary winding to a wound secondary with many turns. Because the gaps in the
hinged segment introduce inaccuracy, such devices are not normally used for revenue
metering. Current transformers, especially those intended for high voltage substation service,
may have multiple taps on their secondary windings, providing several ratios in the same
device. This can be done to allow for reduced inventory of spare units, or to allow for load
growth in an installation. A high-voltage current transformer may have several secondary
windings with the same primary, to allow for separate metering and protection circuits, or for
connection to different types of protective devices. For example, one secondary may be used
for branch over current protection, while a second winding may be used in a bus differential
protective scheme, and a third winding used for power and current measurement.

8. MANPOWER REQUIREMENT:

The enterprise requires 33 employees as detailed below:

Sr. No. Designation Of Salary Per Monthly

Number of employees required
Employees Person Salary ₹
Year-1 Year-2 Year-3 Year-4 Year-5
1 Production Manager 18000 18000 1 1 1 1 1
2 Operators 12000 84000 7 7 7 9 9
3 Helpers 10000 70000 7 7 7 9 9
2 Admin Manager 15000 15000 1 1 1 1 1
Accounts/Stores 3 3 3 4 4
3 12500 37500
Assistant
Office Boy 9000 27000 3 3 3 3 3
Total 251500 22 22 22 27 27
9. IMPLEMENTATION SCHEDULE:

The project can be implemented in 4 months’ time as detailed below:

Sr. No. Activity Time Required

(in months)
1 Acquisition of premises 1.00

2 Construction (if applicable) 1.00

3 Procurement & installation of Plant & Machinery 2.00

4 Arrangement of Finance 2.00

5 Recruitment of required manpower 1.00

Total time required (some activities shall run concurrently) 4.00

10. COST OF PROJECT:

The project shall cost ₹ 77.37lacs as detailed below:

Sr. No. Particulars ₹ in Lacs

1 Land 1000 sq.mtr@ 1000 10.00

2 Building 18.00

3 Plant & Machinery 27.00

4 Furniture, Electrical Installations 3.00

5 Other Assets including Preliminary / Pre-operative expenses 2.70

6 Working Capital 16.67

Total 77.37
11. MEANS OF FINANCE:

Bank term loans are assumed @ 75 % of fixed assets.

Sr. No. Particulars ₹ in Lacs
1 Promoter's contribution 19.34

2 Bank Finance 58.03

Total 77.37

12. WORKING CAPITAL CALCULATION:

Sr. No. Particulars Gross Amt Margin % Margin Amt Bank Finance

1 Inventories 8.33 0.25 2.08 6.25

2 Receivables 4.17 0.25 1.04 3.13

3 Overheads 4.17 100% 4.17 0.00

4 Creditors - 0.00 0.00

Total 16.67 7.29 9.38

13. LIST OF MACHINERY REQUIRED:

Coil Winding Machines, Brazing Machines, Milling machines, Lathe machines, Shaping
machines, Welding machines, Polishing machines, Shearing Machine (Cutting Machine),
Press Brake (Bending Machine), Co2 Welding Equipment, Corner Notching Machine, and
Power Punch Press.
 Rate Value
Sr. No. Particulars UOM Qtty
(₹) (₹ in Lacs)

Plant & Machinery / equipments

a) Main Machinery

i. WINDING DEPARTMENT NO 1 12.00 12.00

ii. MACHINING DIVISION NO 1 6.00 6.00

iii. MILLING AND OTHER DIVISION NO 1 4.50 4.50

iv. FINISHNG DIVISION L.S. 1 1.50 1.50

v. LABORATORY DIVISION NO 1 1.00 1.00

Installation, Electrification, taxes and

vi. L.S. 1 2.00 2.00
transportation.

sub-total Plant & Machinery 27.00

Furniture / Electrical installations

a) Office furniture LS 1 50000 0.50

b) Stores Almirah LS 1 0 0.00

c) Computer & Printer L. S. 5 50000 2.50

sub total 3.00

Other Assets

a) preliminary and preoperative 2.70

sub-total Other Assets 2.70

Total 32.70

All the machines and equipment are available from local manufacturers. The entrepreneur
needs to ensure proper selection of product mix and proper type of machines and tooling to
have modern and flexible designs. It may be worthwhile to look at reconditioned imported
machines, dies and tooling. Some of the machinery and dies and tooling suppliers are listed
here below:
1. Sagar Engineering Works
A-129, Road No. 9 D,
V. K. I. Area, Jaipur - 302013,
Rajasthan, India
Phone: +91-9829024358, +91-141-4064876

2. Uday Enterprises
Khasra No. 1108, Village Makanpur, Behind Indian Child School
Opposite Janta Flat No. 433, Nyay Khand 1,
Indirapuram, Ghaziabad - 201010, Uttar Pradesh, India
Phone: +91-9212320224.

3. Ranoson Machines Private Limited

A-153, Sector 80, Phase 2,
Back Side of Moser Baer Factory, Noida - 201301,
Uttar Pradesh, India
Phone: +91-9811636750, +91-9811080803

4. Krishna Engineering Works

28, Madhuvan, Near Prestige Bungalows
Punit Nagar Crossing Road,
Ghodasar, Ahmedabad - 380050, Gujarat, India
Phone: +91-9824323439
 14. PROFITABILITY CALCULATIONS:

Sr. No. Particulars UOM Year-1 Year-2 Year-3 Year-4 Year-5

1 Capacity Utilization % 60% 70% 80% 90% 100%
2 Sales ₹. In Lacs 60.00 70.00 80.00 90.00 100.00

Raw Materials & Other

3 ₹. In Lacs 48.12 56.14 64.16 72.18 80.20
direct inputs

4 Gross Margin ₹. In Lacs 11.88 13.86 15.84 17.82 19.80

5 Overheads except interest ₹. In Lacs 4.59 4.88 5.45 5.63 5.74

6 Interest ₹. In Lacs 5.80 5.80 3.87 2.90 2.32

7 Depreciation ₹. In Lacs 18.90 13.50 9.45 6.75 6.08

8 Net Profit before tax ₹. In Lacs -17.41 -10.32 -2.93 2.54 5.66

The basis of profitability calculation:

The growth of selling capacity will be increased 10% per year. (This is assumed by various
analysis and study; it can be increased according to the selling strategy.)

Energy Costs are considered at Rs 7 per Kwh and fuel cost is considered at Rs. 65 per liter.
The depreciation of plant is taken at 10-12 % and Interest costs are taken at 14 -15 %
depending on type of industry.

15. BREAKEVEN ANALYSIS:

The project shall reach cash break-even at 40.71 % of projected capacity as detailed below:

Sr. No. Particulars UOM Value

1 Sales at full capacity ₹. In Lacs 100.00

2 Variable costs ₹. In Lacs 80.20

3 Fixed costs incl. interest ₹. In Lacs 8.06
4 BEP = FC/(SR-VC) x 100 = % of capacity 40.71%
 16. STATUTORY / GOVERNMENT APPROVALS

As per the allocation of business rules under the Constitution, labour is in the concurrent list
of subjects. It is dealt with by the MOLE at the Central and Departments of Labour under
State Governments in respective States / UTs. The MOLE has enacted workplace safety and
health statutes concerning workers in the manufacturing sector, mines, ports and docks and
in construction sectors.

Further, other Ministries of the Government of India have also enacted certain statutes
relating to safety aspects of substances, equipment, operations etc. Some of the statutes
applicable in the manufacturing sector are discussed below:

The Manufacture, Storage and Import of Hazardous Electronic Rules (MSIHC),

1989

These MSIHC Rules are notified under the Environment (Protection) Act, 1986. These rules
are aimed at regulating and handling of certain specified hazardous chemicals. The rules
stipulate requirements regarding notification of site, identification of major hazards, taking
necessary steps to control major accident, notification of major accident, preparation of
safety report and on-site emergency plan; prevention and control of major accident,
dissemination of information etc. These rules are notified by the Ministry of Environment and
Forests (MOEF) but enforced by the Inspectorates of Factories of respective States / UTs in
the manufacturing sector. Entrepreneur may contact State Pollution Control Board where
ever it is applicable.

17. BACKWARD AND FORWARD INTEGRATIONS

Both forward and backward integration for any Electrical Industry are strategies to gain
better control over the supply chain, reduce dependency on the suppliers and increase their
competitiveness. The two strategies can help companies reduce their dependency on
suppliers and increase their influence over the customers. The benefits of these strategies
can be big. Both impact the bottom line directly. Integration happens if a company moves
upward or downward in its supply chain. Starting from the suppliers from whom the raw
materials are obtained, the chain moves downstream towards the distributors and the
retailers. If the suppliers’ power is very high, it can create financial burdens for the company.
Suppose the number of suppliers of a company is low, then the control in their hands would
be low. The burden in that case will fall upon company’s shoulders. Its expenditure on raw
materials will be high.

18. TRAINING CENTERS AND COURSES

There is no such training required to start this business but, basic Electrical or IC bachelor’s
degree is plus point for enterpriser. Promoter may train their employees in such specialized
institutions to grow up the business. There are few specialized Institutes provide degree
certification in chemical Technology, few most famous and authenticate Institutions are as
follows:

1. Department Of Electrical LD College Of Engineering

No.120, Circular Road, University Area, Navrangpura,
Opposite Gujarat University, Ahmedabad, Gujarat 380015

2. MIT College Of Engineering, Pune

Gate.No.140, Raj Baugh Educational Complex,
Pune Solapur Highway,
Lonikalbhor, Pune – 412201
Maharashtra, India

Udyamimitra portal ( link : www.udyamimitra.in ) can also be accessed for handholding

services viz. application filling / project report preparation, EDP, financial Training, Skill
Development, mentoring etc.

Entrepreneurship program helps to run business successfully is also available from Institutes
like Entrepreneurship Development Institute of India (EDII) and its affiliates all over India.
Disclaimer:
Only few machine manufacturers are mentioned in the profile, although many machine
manufacturers are available in the market. The addresses given for machinery manufacturers
have been taken from reliable sources, to the best of knowledge and contacts. However, no
responsibility is admitted, in case any inadvertent error or incorrectness is noticed
therein. Further the same have been given by way of information only and do not carry any
recommendation.